CN114833439A - Method for welding high-melting-point dissimilar metal through preset T-shaped full-blocking layer - Google Patents
Method for welding high-melting-point dissimilar metal through preset T-shaped full-blocking layer Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
- B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
- B23K20/1245—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding characterised by the apparatus
- B23K20/1255—Tools therefor, e.g. characterised by the shape of the probe
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/26—Auxiliary equipment
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B5/00—Measuring arrangements characterised by the use of mechanical techniques
- G01B5/02—Measuring arrangements characterised by the use of mechanical techniques for measuring length, width or thickness
Abstract
The invention provides a method for welding high-melting-point dissimilar metals by presetting a T-shaped full barrier layer, which comprises the following steps of: step 1, selecting a dissimilar metal initial plate, selecting a soft metal plate and obtaining an applicable T-shaped full-blocking layer through a milling process; step 2, assembling the initial plate and the soft T-shaped full barrier layer; step 3, selecting welding parameters of friction stir welding; and 4, starting the machine tool to carry out friction stir welding processing, and carrying out welding according to a set track to form a reliable joint. The soft T-shaped full-blocking layer is arranged at the contact interface of the welding tool and the welded material, so that the direct strong action between the welding tool and the high-melting-point metal is avoided, various problems of welding load during welding of the high-melting-point dissimilar metal are solved, and high-quality reliable welding of the dissimilar metal is realized.
Description
Technical Field
The invention belongs to the technical field of friction stir welding, and particularly relates to a method for welding high-melting-point dissimilar metals by presetting a T-shaped full-blocking layer.
Background
With the rapid development of modern industry, stricter application requirements are put forward on various engineering parts. In many cases, a single metal material cannot meet the use requirements of engineering, and a welding method is used for manufacturing a dissimilar metal component. The dissimilar metal welding structure can meet the performance requirements of industrial designers on a single material, can meet the special requirements of different materials on different working conditions, improves the bearing capacity of a welding structural member and saves cost, and therefore the dissimilar metal welding structure becomes the focus of attention in the modern industrial field.
According to the traditional dissimilar metal welding method, the method can be generally divided into three categories: fusion welding, pressure welding, brazing, and the like. In practical engineering application, the fusion welding application ratio is the largest. However, due to the large difference in the thermal properties such as melting point, thermal conductivity, expansion coefficient, shrinkage ratio, etc. of dissimilar metals, it is difficult to obtain a high-performance welded joint by these conventional fusion welding methods, and the following problems are reflected specifically: (1) the heat conductivity difference of dissimilar metals is too large, so that the metallurgical bonding is difficult, and the performance of a welding joint is reduced; (2) when dissimilar metals with excessively large melting point differences are welded, permeation cracks are easily formed in a heat affected zone on the high-melting-point metal side, and the service life of a welding joint is shortened; (3) after welding, the metal with large linear expansion coefficient can have large residual stress, cracks are easy to generate, and the peeling between a welding line and base metal can be caused seriously; (4) when a dissimilar material such as copper-steel is welded by selecting large-specification welding parameters, the coarsening of crystal grains in a heat affected zone is easy to be serious, and copper in a welding seam area is easy to oxidize to form Cu 2 Low melting point eutectic such as O, causes deterioration of joint performance.
In addition to the conventional welding methods, better welding quality can be obtained by using methods such as laser welding, diffusion welding and the like, but the methods have the disadvantages of high welding cost, low efficiency, strict process requirements and complicated process parameters, and are not favorable for large-scale mechanized production. Based on the shortcomings of conventional welding, some researchers have proposed methods of welding high melting point metals using friction stir welding.
The friction stir welding is a novel solid welding, is insensitive to the influence of physical and chemical properties, mechanical properties and the like of materials, and can well overcome the welding difficulty caused by the difference of the welding properties of different materials. For example, Pawanyun et al (hot working technology, 2011,40(22):91-93) mentioned that the friction stir lap welding is used for welding red copper and low carbon steel, and a joint with good quality is obtained. Meanwhile, Zhou Li (journal of welding, 2019,40(04):22-27+ 161-; joshi G R et al (Metallographics, Micromicroscopy, and Analysis,2017,6(6): 470-. In combination with most of the currently available studies, it has been found that, although friction stir welding exhibits great advantages in the welding of dissimilar metals, it still faces the problems of non-synchronization of the deformation characteristics of the bonding tool and the two materials at different friction surfaces, poor durability of the bonding tool material, formation of harmful intermetallic compounds, and reduced performance of the weld zone.
Patent CN103846542A discloses a method for welding aluminum and other high melting point metals by using a stirring pin with a specific end shape, setting a constant axial pressure of the stirring pin, using a non-inclination welding mode and designing an involute groove at the end of a shaft shoulder, which greatly reduces the abrasion of the stirring pin, but the method is somewhat tedious and has great difficulty in use, and meanwhile, the method mainly aims at welding aluminum and other high melting point metals and has certain limitations. Patent CN113231753A is when welding the dissimilar metal, at first carries out hot dipping metallization to the hard metal board, and then pile up the build-up layer that a layer welding wire composition is mainly another kind of soft metal on it, carries out friction stir lap welding with hard metal and soft metal again, because the stirring pin mainly acts on in the soft build-up layer, has reduced the wearing and tearing of stirring pin, has improved the intensity that connects simultaneously to a certain extent, but this method is comparatively complicated, difficult operation, and it is limited to connect intensity promotion.
Disclosure of Invention
The technical task of the invention is to provide a method for welding high-melting-point dissimilar metals by presetting a T-shaped full barrier layer aiming at the defects of the prior art. The soft T-shaped full-blocking layer is arranged at the contact interface of the welding tool and the welded material, so that the direct strong action between the welding tool and the high-melting-point metal is avoided, various problems of welding load during welding of the high-melting-point dissimilar metal are solved, and high-quality reliable welding of the dissimilar metal is realized.
The technical scheme adopted by the invention for solving the technical problems is as follows: a method for welding high-melting-point dissimilar metals by presetting a T-shaped full barrier layer comprises the following steps:
s1, selecting a soft metal plate, processing to obtain a T-shaped full-blocking layer, and pre-arranging the T-shaped full-blocking layer between two high-melting-point metal initial plates to be connected;
s2, assembling the initial plates and a T-shaped full blocking layer, wherein the T-shaped full blocking layer comprises a vertical straight part and a horizontal straight part, the vertical straight part is in butt joint with the end parts of the two initial plates, and two sides of the horizontal straight part are respectively lapped on the two initial plates; after assembly, fixing the two initial plates and the T-shaped full-blocking layer on a workbench together by adopting a welding tool;
and S3, setting welding parameters of friction stir welding, starting a machine tool, moving the stirring head to an initial welding position, wherein the initial welding position is a horizontal straight part above a vertical straight part of the T-shaped full-blocking layer, penetrating the T-shaped full-blocking layer at a set rotating speed, moving the stirring head, and welding according to a set track.
Further, in the step S1, the two initial plates have the same thickness, the thickness range is 1-10 mm, and the height of the vertical straight line part of the T-shaped full-blocking layer is the same as the thickness of the initial plates.
Further, the two initial plates in the step S1 are pure metals or alloys of different materials, specifically any two of carbon steel, alloy steel, copper and copper alloy, aluminum and aluminum alloy, magnesium alloy, and titanium alloy; the soft metal in step S1 is any one of aluminum and aluminum alloy, magnesium and magnesium alloy.
Further, the width of the horizontal line portion of the T-shaped full barrier layer in step S2 is not less than the diameter of the shoulder, and the length is not less than the length of the weld.
Further, the width of the vertical line part of the T-shaped full barrier layer in the step S2 is 1-2 mm, and the minimum diameter of the stirring pin is larger than the width of the vertical line part.
Further, in the two initial sheet materials in step S2, the sheet metal material with higher hardness and melting point is placed on the advancing side, and the other sheet metal material is placed on the retreating side.
Further, in the step S2, the lower surfaces of both sides of the horizontal line portion of the T-shaped full barrier layer are in close contact with the upper surface of the initial plate located below the T-shaped full barrier layer, and both side surfaces of the vertical line portion of the T-shaped full barrier layer are in close contact with the end surfaces of the two initial plates respectively.
Further, the welding parameters in step S3 are: the inclination angle of a main shaft of the welding machine is 0-3 degrees, the rotating speed of a welding tool stirring head is 100-2000 rpm, the advancing speed of the welding tool stirring head is 100-1000 mm/min, and the shaft shoulder pressing-in amount of the welding tool is 0.1-0.3 mm.
Further, the diameter of the shaft shoulder of the welding tool in the step S3 is 2-6 times of the total height of the T-shaped full barrier layer; the length of the stirring pin of the welding tool in the step S3 is 0.1-0.3 mm shorter than the total height of the T-shaped full barrier layer.
Furthermore, the initial welding position in the step 4 is a horizontal straight part right above the vertical straight part of the T-shaped full-blocking layer, and the central axis of the stirring pin and the central line of the vertical straight part are on the same straight line.
Compared with the prior art, the method for welding the high-melting-point dissimilar metal by presetting the T-shaped full barrier layer has the beneficial effects that:
(1) the soft T-shaped full-blocking layer is arranged at the contact interface of the welding tool and the welded material, so that the direct strong action between the shaft shoulder and the stirring pin of the welding tool and the high-melting-point metal is avoided, the welding load is effectively reduced, the abrasion of the welding tool is weakened, the welding heat production is reduced, the formation of harmful intermetallic compounds in a welding seam is inhibited, the problems of large welding load, high welding heat production, serious abrasion of the welding tool, low welding seam performance and the like in the welding of the high-melting-point dissimilar metal are solved, and the high-quality reliable welding of the high-melting-point dissimilar metal is realized.
(2) The welding method of the dissimilar metal with the high melting point is convenient to operate, low in cost, good in realizability and suitable for large-scale popularization and application.
Drawings
FIG. 1 is a schematic view of the method for welding high melting point dissimilar metals by presetting a T-shaped full barrier layer according to the invention;
FIG. 2 is a schematic representation of the major dimensions of a T-shaped total barrier layer and an initial sheet material according to the present invention;
FIG. 3 is a graph showing the hardness distribution of the joint in each zone according to the examples of the present invention, (a) example 1, (b) example 2, and (c) example 3;
FIG. 4 is an X-ray diffraction pattern at a tensile break of a joint obtained in accordance with various embodiments of the present invention, (a) example 1, (b) example 2, (c) example 3;
FIG. 5 is a scanning electron microscope image of a weld receding side obtained in an embodiment of the present invention, (a) example 1, (b) example 2, and (c) example 3.
Reference numerals: 1-an initial plate I, 2-an initial plate II, 3-a T-type full barrier layer, 4-a T-type full barrier layer vertical straight part, 5-a welding tool stirring head, 6-a welding tool shaft shoulder, 7-a stirring pin, 8-a backward side, 9-a forward side, 10-a T-type full barrier layer horizontal straight part left side lower surface, 11-a T-type full barrier layer horizontal straight part right side lower surface, 12-an initial welding position, 13-a T-type full barrier layer vertical straight part left side surface, 14-a T-type full barrier layer vertical straight part right side surface, 15-an initial plate I upper surface, 16-an initial plate II upper surface, 17-an initial plate I right side surface, 18-an initial plate II left side surface;
d-diameter of shaft shoulder of welding tool, L-length of stirring pin of welding tool, D 1 Root diameter of the stirring pin, d 2 -the diameter of the stirring pin end,total height of H-T type full barrier layer H 1 Height of vertical line of T-shaped full barrier layer, h 2 -the height of the horizontal line of the T-shaped full barrier layer, the width of the vertical line of the w-T-shaped full barrier layer and delta-the thickness of the initial plate.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is further described in detail with reference to the following embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
Example 1
A method for welding high melting point dissimilar metals by presetting a T-shaped full barrier layer, as shown in figures 1 and 2, comprising the following steps:
step 1, material selection: as shown in fig. 1, T2 pure copper is selected as an initial plate I1, 304 galvanized steel is selected as an initial plate II2, and the thickness δ is 1 mm; selecting a 7B04 aluminum alloy plate, obtaining a suitable T-shaped full barrier layer 3 through a milling process, and pre-arranging the T-shaped full barrier layer 3 between two initial plates to be connected, wherein as shown in figure 2, the total height H of the T-shaped full barrier layer 3 is 2.8mm, and the height H of the vertical straight part 4 is 1 1mm, 1mm in width w, and a height h of a horizontal straight part 2 Is 1.8mm, the width is not less than the diameter D of the shaft shoulder, and the length is not less than the length of the welding seam;
and 4, starting welding: and starting the machine tool to move the stirring head 5 to an initial welding position 12, wherein the initial welding position is a horizontal straight part right above a vertical straight part of the T-shaped full-blocking layer, the central axis of the stirring needle and the central line of the vertical straight part are positioned on the same straight line, the stirring needle penetrates into the T-shaped full-blocking layer 3 at the rotating speed of 800rpm, and when the penetration depth of the shaft shoulder 6 of the welding tool is 0.2mm, the stirring head 5 moves at the advancing speed of 100mm/min to perform welding according to a set track.
Example 2
A method for welding high melting point dissimilar metals by presetting a T-shaped full barrier layer, as shown in figures 1 and 2, comprising the following steps:
step 1, material selection: as shown in fig. 1, T2 pure copper is selected as an initial plate I1, 304 galvanized steel is selected as an initial plate II2, and the thickness δ is 1 mm; selecting a 7B04 aluminum alloy plate, obtaining a suitable T-shaped full barrier layer 3 through a milling process, and pre-arranging the T-shaped full barrier layer 3 between two initial plates to be connected, wherein as shown in figure 2, the total height H of the T-shaped full barrier layer 3 is 2.8mm, and the height H of the vertical straight part 4 is 1 1mm, 1mm in width w, and a height h of a horizontal straight part 2 1.8mm, the width is not less than the diameter D of the shaft shoulder, and the length is not less than the length of a welding seam;
and 4, starting welding: and starting the machine tool to move the stirring head 5 to an initial welding position 12, wherein the initial welding position is a horizontal straight part right above a vertical straight part of the T-shaped full-blocking layer, the central axis of the stirring needle and the central line of the vertical straight part are positioned on the same straight line, the stirring needle penetrates into the T-shaped full-blocking layer 3 at the rotating speed of 800rpm, and when the penetration depth of the shaft shoulder 6 of the welding tool is 0.2mm, the stirring head 5 moves at the advancing speed of 200mm/min to perform welding according to a set track.
Example 3
A method for welding high melting point dissimilar metals by presetting a T-shaped full barrier layer, as shown in figures 1 and 2, comprising the following steps:
step 1, material selection: as shown in fig. 1, T2 pure copper is selected as an initial plate I1, 304 galvanized steel is selected as an initial plate II2, and the thickness δ is 1 mm; selecting a 7B04 aluminum alloy plate, obtaining a suitable T-shaped full barrier layer 3 through a milling process, and pre-arranging the T-shaped full barrier layer 3 between two initial plates to be connected, wherein as shown in figure 2, the total height H of the T-shaped full barrier layer 3 is 2.8mm, and the height H of the vertical straight part 4 is 1 1mm, 2mm in width w and a height h of the horizontal straight part 2 1.8mm, the width is not less than the diameter D of the shaft shoulder, and the length is not less than the length of a welding seam;
and 4, starting welding: and starting the machine tool to move the stirring head 5 to an initial welding position 12, wherein the initial welding position is a horizontal straight part right above a vertical straight part of the T-shaped full-blocking layer, the central axis of the stirring needle and the central line of the vertical straight part are positioned on the same straight line, the stirring needle penetrates into the T-shaped full-blocking layer 3 at the rotating speed of 800rpm, and when the penetration depth of the shaft shoulder 6 of the welding tool is 0.2mm, the stirring head 5 moves at the advancing speed of 200mm/min to perform welding according to a set track.
And (3) postweld detection:
the hardness distribution of the joint obtained in examples 1, 2 and 3 was measured after welding in each region of the joint, and as shown in fig. 3, the average hardness of the copper base material was: 84.5HV, the average hardness of the steel base material is: 178.3 HV. The average hardness of the center weld zone of the joint of example 1 was: 151.5HV, minimum hardness: 137.6HV, maximum hardness: 176 HV; the average hardness of the center weld zone of the joint of example 2 was: 149.9HV, minimum hardness: 132.1HV, maximum hardness: 153.5 HV; the average hardness of the center weld zone of the joint of example 3 was: 150.7HV, minimum hardness: 137.8HV, maximum hardness: 175.3 HV. The hardness values of the central welding seam areas of the joints obtained by the three implementation cases are all between the steel base metal and the copper base metal. Through tensile test, the average breaking strength of the welding seam area of the joint welded by the preset T-shaped full barrier layer is 217.7MPa, and the breaking strength loss of the joint is in an allowable range. The weld quality was good from the hardness and tensile results.
The stirring pins of the welding tool of the three embodiments were measured with a vernier caliper, and the length before welding was 2.60mm and the length after welding was 2.60mm, and there was substantially no wear.
The tensile fracture of the joint obtained in examples 1, 2 and 3 was analyzed by X-ray diffraction, and the X-ray diffraction results are shown in FIG. 4. For example 1, the compound was mainly Al 2 Cu、Al 4 Cu 9 And the like, almost no harmful copper steel compounds; for example 2, there was almost no compound at the fracture; for example 3, the compound was mainly Al 2 Cu、Al 4 Cu 9 And the like, and almost no harmful copper-steel compounds exist. Microscopic analysis is carried out on the welding seam by using a scanning electron microscope, the scanning electron microscope images of the examples 1, 2 and 3 are shown in figure 5, observation and analysis are carried out, and the results of X-ray diffraction analysis are combined, so that only one layer of continuous aluminum-copper compound with the thickness of about 1 mu m exists on the retreating side of the welding seam in the example 1, and the content of the compound is low; in both examples 2 and 3, only one layer of continuous aluminum copper compound with the thickness slightly lower than 1 μm exists on the retreating side of the welding seam, and the content of the compound is lower.
The technical idea of the present invention is described in the above technical solutions, and the protection scope of the present invention is not limited thereto, and any changes and modifications made to the above technical solutions according to the technical essence of the present invention belong to the protection scope of the technical solutions of the present invention.
Claims (10)
1. A method for welding high-melting-point dissimilar metals by presetting a T-shaped full-blocking layer is characterized in that:
the method comprises the following steps:
s1, selecting a soft metal plate, processing to obtain a T-shaped full-blocking layer, and pre-arranging the T-shaped full-blocking layer between two high-melting-point metal initial plates to be connected;
s2, assembling the initial plates and a T-shaped full blocking layer, wherein the T-shaped full blocking layer comprises a vertical straight part and a horizontal straight part, the vertical straight part is in butt joint with the end parts of the two initial plates, and two sides of the horizontal straight part are respectively lapped on the two initial plates; after assembly, fixing the two initial plates and the T-shaped full-blocking layer on a workbench together by adopting a welding tool;
and S3, setting welding parameters of friction stir welding, starting a machine tool, moving the stirring head to an initial welding position, wherein the initial welding position is a horizontal straight part above a vertical straight part of the T-shaped full-blocking layer, penetrating the T-shaped full-blocking layer at a set rotating speed, moving the stirring head, and welding according to a set track.
2. The method for welding the high melting point dissimilar metals by the preset T-shaped full barrier layer according to the claim 1, is characterized in that: in the step S1, the two initial plates are the same in thickness, the thickness range is 1-10 mm, and the height of the vertical straight part of the T-shaped full-blocking layer is the same as the thickness of the initial plates.
3. The method for welding the high melting point dissimilar metals by the preset T-shaped full barrier layer according to the claim 1, is characterized in that: the two initial plates in the step S1 are pure metals or alloys of different materials, specifically any two of carbon steel, alloy steel, copper and copper alloy, aluminum and aluminum alloy, magnesium alloy, and titanium alloy; the soft metal in step S1 is any one of aluminum and aluminum alloy, magnesium and magnesium alloy.
4. The method for welding the high melting point dissimilar metals by the preset T-shaped full barrier layer according to the claim 1, is characterized in that: the width of the horizontal straight part of the T-shaped full barrier layer in the step S2 is not less than the diameter of the shaft shoulder, and the length is not less than the length of the welding seam.
5. The method for welding the high melting point dissimilar metals by the preset T-shaped full barrier layer according to the claim 1, is characterized in that: the width of the vertical straight part of the T-shaped full barrier layer in the step S2 is 1-2 mm, and the minimum diameter of the stirring needle is larger than the width of the vertical straight part.
6. The method for welding the high melting point dissimilar metals by the preset T-shaped full barrier layer according to the claim 1, is characterized in that: in the two initial plates in the step S2, the metal plate with higher hardness and melting point is placed on the advancing side, and the other metal plate is placed on the retreating side.
7. The method for welding the high melting point dissimilar metals by the preset T-shaped full barrier layer according to the claim 1, is characterized in that: in the step S2, the lower surfaces of both sides of the horizontal line-shaped portion of the T-shaped full barrier layer are in close contact with the upper surface of the initial plate located below the T-shaped full barrier layer, and both side surfaces of the vertical line-shaped portion of the T-shaped full barrier layer are in close contact with the end surfaces of the two initial plates respectively.
8. The method for welding the high melting point dissimilar metals by the preset T-shaped full barrier layer according to the claim 1, is characterized in that: in the step S3, the welding parameters are: the inclination angle of a main shaft of the welding machine is 0-3 degrees, the rotating speed of a welding tool stirring head is 100-2000 rpm, the advancing speed of the welding tool stirring head is 100-1000 mm/min, and the shaft shoulder pressing-in amount of the welding tool is 0.1-0.3 mm.
9. The method for welding the high melting point dissimilar metals by the preset T-shaped full barrier layer according to the claim 1, is characterized in that: the diameter of the shaft shoulder of the welding tool in the step S3 is 2-6 times of the total height of the T-shaped full barrier layer; in the step S3, the length of the stirring pin of the welding tool is 0.1-0.3 mm shorter than the total height of the T-shaped full barrier layer.
10. The method for welding the high melting point dissimilar metals by the preset T-shaped full barrier layer according to the claim 1, is characterized in that: and 4, the initial welding position of the step 4 is a horizontal straight part right above the vertical straight part of the T-shaped full-blocking layer, and the central axis of the stirring pin and the central line of the vertical straight part are positioned on the same straight line.
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